Large Wind Turbine Generator Shell for Protection of Components Inside

Overview of Large Wind Turbine Generator Shell

The casing of a wind turbine generator, also known as the wind turbine nacelle or wind turbine generator nacelle, is an important component of large wind turbine generators. It covers and protects the equipment and electrical components inside the wind turbine generator and is installed on the top of the tower located at a high altitude. Its main function is to protect the internal equipment from external environmental factors, ensuring the smooth operation of the wind turbine generator. Wind turbine nacelle covers feature high specific strength, aging resistance, good appearance and light weight.

1. Material and casting process of Large Wind Turbine Generator Shell

The shell base is made of ductile iron QT500-7 material. The tensile strength of a single cast piece weighs up to 12 tons, exceeding 500MPa, and the elongation exceeds 7% of the toughness index, ensuring that the shell maintains structural integrity even when subjected to a hurricane impact of 60 meters per second. The measured data of the Zhangbei Wind Farm in Hebei Province shows that the impact toughness of the casing of the units using the integral casting process has increased by 40% compared with the traditional welded structure in the extremely low temperature of minus 35℃. Precision sand casting technology gives the structure advantages of the shell. The spiral flow channel integrated heat dissipation structure developed by a heavy industry company in Shandong Province forms a cooling channel with a total length of 328 meters inside the shell through the casting process. Combined with the design of the outer wall thickness gradient change, the operating temperature of the equipment is reduced by 18℃. This circulation system that “grows” inside the metal increases the heat dissipation efficiency to 2.3 times that of traditional external cooling devices.

2. The Function of Large Wind Turbine Generator Shell

The functional integration demonstrates the inclusiveness of the metal intelligent casting process, enabling the shell to break through its single protective function. Two hundred eighty-seven stress monitoring points are pre-embedded in the casting casing of the Rudong Wind Farm in Jiangsu Province. The FBG optical fiber sensors implanted during the casting stage form a symbiotic structure with the metal substrate, achieving full life cycle strain monitoring. The deep integration of this metal and optoelectronics enables the accuracy of structural health assessment to reach the 0.01mm level. In the bohai bay salt fog corrosion area, casting shell surface using micro-arc oxidation, organic silicon compound treatment technology, formation of 12 microns thick ceramic protective layer. After 2000 hours of salt spray test, the corrosion rate was controlled at 0.003mm/ year, which improved the durability by 8 times compared with the ordinary coating scheme. Even more exquisitely, the shark skin bionic texture casting on the shell surface reduces the turbulence intensity by 21% and increases the annual power generation by 3.7%.

3. Environmental Adaptation of Large Wind Turbine Generator Shell

To the harsh environment of the Qinghai-Tibet Plateau with a temperature difference of 60℃ between day and night, the Tibet Cuomei Wind Power Project adopts a double-layer hollow casting structure. The phase change energy storage material in the 8-cm air interlayer absorbs excess heat during the day and releases it at night to maintain the constant temperature of the equipment. This “breathing” shell design successfully keeps the temperature fluctuation inside the cabin within ±2℃. Wind farms in the south China sea island of casting, show another wisdom. A special formula with 3% copper element is added during the casting process, combined with a surface cathodic protection system, to construct a three-dimensional anti-corrosion system. Actual operation data shows that in a sea fog environment with a chloride ion concentration as high as 3.5mg/m³, the annual corrosion of the shell is only 0.12mm, and the design life is extended to 30 years.

4. Technological Innovation of Large Wind Turbine Generator Shell

Reshapes the Metal Body Currently, casting technology is breaking through physical boundaries. The gradient casting process developed by Shenyang Foundry Research Institute enables different parts of a single shell to exhibit differentiated performance: the Brinell hardness of the 20mm thickness area on the windward side reaches HB220, while the toughness of the 15mm area on the leeward side is maintained at HB180. This “combination of rigidity and flexibility” feature has enhanced the overall fatigue resistance of the machine by 35%. More cutting-edge intelligent casting technology is rewriting industry rules. A certain enterprise in Xiangyang, Hubei Province, implanted memory alloy prefabricated parts into the casting process. When the ambient temperature exceeded 50℃, the 1072 micro-scales on the surface of the shell automatically opened, forming a dynamic heat dissipation channel. This bionic design extends the continuous operation time of the unit by 42% in tropical regions and the maintenance cycle exceeds 40,000 hours. From the sand mould to intelligence, from single to the system, fan shell castings evolution is a microcosm of the industrial civilization. When 3D sand mold printing technology achieves precision control at the 0.1mm level and the online monitoring system for casting defects reduces the scrap rate to 0.03%, this thousand-year-old process is rejuvenating in the field of new energy.

Specifications of  Wind Power Generator Shell
Structure & Material
Shell Material	strength of extension	Surface Treatment Technology	Structural Form
Ductile iron QT500-7	500MPa	Spray/anodizing/galvanizing (salt spray resistance ≥1000 hours)	Split modular design/integral welded type
Size & Weight
Gross Weight	Overall Dimensions (L×W×H)	Mounting Interface Size
800-2500 kg	3000×1500×2000 mm (customized size)	Flange standards (e.g. ISO 5210)
Environmental Suitability & Adaptation
Operating Temperature	Humidity Range	Salt Spray Resistance	Lightning Protection Design
(-)40° to 60°	≤95% RH (non-condensing)	≥2000 Hours (ASTM B117 standard)	Integrated ground terminal (resistance ≤4Ω)

Package of Large Wind Turbine Generator Shell

Polybag+Carton box+Wooden case/Pallet, according to customer’s request

Company Profile

Luoyang Fonyo Heavy Industries Co., Ltd. was founded in 1998, covers an area of 72,600㎡, with more than 300 employees, 32 technicians, including 5 senior engineers, 11 assistant engineers, and 16 technicians. It has been rated as Luoyang Engineering Technology Center, Luoyang Technology R&D Center, and National High-tech Enterprise for many times.
Our production capacity is 30,000 tons per year. Currently, we mainly produce cast steel, cast iron (gray iron, ductile iron, etc.), processing of finished product and component assembly.the products have been exported to Russia, the United States, Germany, Argentina, Japan, France, South Africa,Italy and other countries.

FAQS

Q1: Are you a manufacturer or trading company?
A:We are a manufacturer. Our company was founded in 1998, with nearly 30 years in casting industry, a total area of 72,600㎡, with a factory building area of 51,000㎡.
Q2. What are your main products?
A: We primarily focus on steel casting, iron casting, finished product machining, and component assembly production.
Q3: How precision can you produce casting parts?
A: We have the capability of producing casting parts with different casting processes. The production is strictly comply with ISO 9001, ISO 14001 and ISO45001,EN15085, IRIS.
Q4. Can you produce according to the samples?
 Yes, we can produce by your samples or technical drawings. We can build drawings for you after we get your samples too.
Q5: How do you do Quality Control before delivery?
A: Quality inspection is a very important factor to guarantee the quality of steel casting parts. We follow 3 times of inspection during the whole production process. And we will provide material testing report, dimensional testing report, and mechanical properties testing report to our clients before delivery.

It you are interested in any products,please feel free to contact us.
Contact:Cathy Xu
Email:sales@railwaypart.com
Mobile:008615515321683